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You are on page 1of 70

This is to certify that the work in the thesis entitled, Flow characteristics study of

fly ash slurry in hydraulic pipelines using computational fluid dynamics

submitted by Sharon A Badarudeen is a record of an original research work carried

out by him during 2013 - 2014 under my supervision and guidance in partial fulfillment

of the requirements for the award of the degree of Master of Technology in Mining

Engineering, National Institute of Technology Rourkela. Neither this thesis nor any part

of it has been submitted for any degree or academic award elsewhere.

ACKNOWLEDGMENT

In pursuit of this academic endeavor, I feel singularly fortunate.

throughout my career.

my course work.

Finally, I humbly bow my head with utmost gratitude before the God

Sharon A Badarudeen

IV | P a g e

ABSTRACT

Transportation of fly ash slurry via pipelines has been recognized as a potential economical and

dependable mode of solid transportation. It also bids various other advantages over the

conventional means of transportation. For improved understanding of the flow characteristics of

these pipelines, investigators throughout the world have been analyzing the flow experimentally

numerically and theoretically. Slurry pipeline systems are regularly used crosswise the world for

the transportation of fly ash from the power plant to the ash ponds. These pipeline are very much

energy exhaustive and also leads to disproportionate and inordinate wear of pipelines and

wastage of water.

Objective of the present work is to conduct a methodical and logical study of fly ash slurry

transportation in a pipeline at higher concentrations by the use of computational fluid dynamics

and study the flow characteristics and pressure drops. An effort has been made in this study to

develop comprehensive slurry flow model using CFD and utilize the model to predict pressure

drop and validating the results with the calculated results. A broad computational fluid dynamics

(CFD) model was established in the current study to gain understanding into the solid liquid

slurry flow in pipelines.

The approach adopted in here is studying and solving the problem by mathematical modeling

method. In this work, the solid suspension in a fully developed pipe flow was simulated and

analyzed

A 20m pipe with a diameter of 0.5m is modeled, through which flow is conducted where

modelling and meshing is done using ANSYS Fluent. High viscosity fly ash slurry with five

different concentrations, 50%, 60%, 65%, 68% and 70% by weight of fly ash is passed and for

each concentration five different velocities like 3, 3.5, 4, 4.5 and 5 m/s are used and pressure

drops are calculated. Other characteristics studied are volume fraction, eddy viscosity and

turbulence kinetic energy.

Keywords: Computational fluid dynamics, Eulerian-Eulerian approach, pressure drop, fly ash,

viscosity.

V|Page

Contents

CONTENTS

Title Page No

Certificate III

Acknowledgement IV

Abstract V

List of Figures IX

Abbreviations XI

Nomenclatures XII

VI | P a g e

Contents

VII | P a g e

Contents

5.1 Conclusion 52

References 54-57

VIII | P a g e

LIST OF FIGURES

LIST OF FIGURES

Figure 3.6 (a) Pipe geometry along the length, (b) Pipe geometry a planar view 36

Figure 4.1 Comparison between calculated and simulated pressure drop at 50%

Concentration 41

Figure 4.3 Comparison between calculated and simulated pressure drop at 60%

Concentration 42

Figure 4.5 Comparison between calculated and simulated pressure drop at 65%

Concentration 43

IX | P a g e

LIST OF FIGURES

Figure 4.7 Comparison between calculated and simulated pressure drop at 68%

Concentration 44

Figure 4.9 Comparison between calculated and simulated pressure drop at 70%

Concentration 45

Figure 4.11 Simulated values of pressure drop variation for fly ash slurry at

different concentrations 46

Figure 4.12 Calculated values of pressure drop variation for fly ash slurry at

different concentrations 46

X|Page

ABBREVIATIONS

ABBREVIATIONS

Re Reynolds Number

St Stokes Number

XI | P a g e

NOMENCLATURES

NOMENCLATURES

Epsilon

Omega

u Velocity of fluid

p Pressure

g Gravity vector.

Volume fraction

F Force

Cw Concentration by weight

XII | P a g e

Introduction

CHAPTER 1

INTRODUCTION

1|Page

Introduction

In a thermal power station or a thermal power plant steam is the prime mover. Every day a huge

quantity of coal is burned which produces ash, now and again being as much as 10 to 20% of the

total amount of coal burned. Ash is present in all available forms of coal. Whenever coal is burnt

in thermal power plant or in a boiler furnace it gives ash as a share of 10 to 20% of coal burnt.

As the modern thermal power plants and large steam power plants where abundant amount of

coal is burnt, the share of ash may go up to a range of thousands of tons per year. When we

consider the case of India we can see that of the total electrical energy is produced from the

thermal power plant which in turn produces a share of 170 million tons of fly ash as solid

leftover yearly. Ash handling and disposal has always been a task for any industries using coal as

the prime fuel. Figure 1.1 depicts a schematic view of ash production in power plants.

Figure 1.1: Power plant utilizing coal for production of electricity [1]

2|Page

Introduction

In coal-fired power plants, Combustion of coal produces materials called as Coal Combustion

Residuals (CCR), which are otherwise called as Coal Combustion Products (CCP). The materials

which come under this category are:

Fly Ash

Bottom Ash

Boiler Slag

Flue Gas Desulfurization Material (FGD)

Material such as fluidized bed combustion ash and scrubber residues

There are a lot of differences in features and physical properties of CCRs. Beneficial reuse of

building materials and replacement for other components like sand, gravel, or gypsum is

determined by their size, shape, and chemical composition.

Management Program Implementation). It also leads to generation of environmental, economic

and performance benefits significantly. Coal combustion residuals can be substituted for another

product using CCRs involvement based on performance criteria.

The physical description of fly ash is that it is a very fine powdery material having the

composition of silica (mostly) being spherically shaped. Presence of silt-sized and clay-sized

glassy spheres give the fly ash a light tan colour thereby making it consistent with talcum

powder. Fly ash is produced by burning finely ground coal in a boiler furnace to produce

electricity. Primarily devices like electrostatic precipitators or bag houses remove exhaust gases

from the plant and secondarily scrubber systems serve for the same.

Ordinary temperatures and presence of water makes fly ash a siliceous material react with

calcium hydroxide producing cementatious compounds. Fly ash has an extensive role to play in

cement and concrete usages mostly for its spherical shape and pozzolanic properties. These

3|Page

Introduction

properties make it a good mineral filter which is used in hot mix asphalt usages thereby leading

to the improvement in fluidity of flow able fill and grout in cases of use of these applications.

Feed stock in manufacture of cement

Fill material for structural uses and embankments

Constituent in waste stabilization

Element in soil alteration and stabilization

Constituent of flow able fill

Constituent in road bases and pavements

Mineral putty in asphalt

The bottom ash is an agglomerated ash element, molded in milled coal furnaces. The bottom ash

are comparatively too large and cannot be carried in the flue gases. They impose on the furnace

walls or drop through open lattices where an ash hopper is there at the bottom of the furnace.

Physically, bottom ash can be described as classically grey black in colour, being moderately

angular in structures, and having a porous surface structure.

Bottom ash varies with fine sand grain sizes to fine gravel grain sizes. Bottom ash is well graded

to meet gradation demands thereby avoiding the want of blending with other aggregates. Unlike

conventional aggregates the bottom ash having structure of porous surface are different to

wearing surface mixtures makes-

More suitable in base course,

Suitable for use in shoulder mixtures,

Suitable for many cold mix applications

Lighter than conventional aggregate

4|Page

Introduction

Constituent in road bases and pavements

As a feed stock in the making cement

Constituent of lightweight concrete goods

Snow and ice traction regulator material

The boiler slag is described as a composition of hard, black, angular particles giving a smooth,

glassy outlook. The slag tap and cyclone type furnace produces the bottom ash at the base in

molten form generally referred to as boiler slag.

Physically boiler slag, a black granular material can be described to be hard, uniformly sized and

durable resisting to surface wear. Permanent black colour in boiler slag is highly required for

asphalt applications thereby helping in snow melting. Removal from service of old power plants

producing boiler slag has decreased its supply value.

Mineral putty in asphalt

Seal material for structural uses and embankments

Raw material in concrete goods

Snow and ice traction control substance

In coal fired boilers for avoiding SO2 emissions from the exhaust gas systems refers to a process

whose product is otherwise called as Flue Gas Desulfurization (FGD) material. A varying range

from wet sludge to a dry powdered material decides the physical nature of FGD depending upon

the process.

5|Page

Introduction

The dry material from dry scrubbers consists of a mixture of sulfites and sulfates that is captured

in a bag house. This powdery substance is mostly called as dry FGD Material, lime spray dryer

ash or dry FGD ash. FGD gypsum constitutes small, fine particles.

Calcium sulfate FGD material can be used as a substitute for gypsum in the production of

cement. Once it has undergone dewatering, it can be utilized for wallboard manufacturing, which

is the largest single market for FGD material. Calcium sulfite FGD material finds its use as an

embankment and road base material

Seal material for structural usages and embankments

Feed stock in manufacturing of cement

Raw material in concrete goods and grout

Constituent in waste stabilization

Choice of pumping arrangement for any slurry transportation is overseen more by the practical

concerns rather than chastely on economic concerns of supreme efficiency. However, discharge

pressure and abrasivity are the two significant factors for the selection of a pump. The main

differences of slurry pumps from conventional pumps are:

Having a heavier shaft

Minimum impeller overhang

More corrosion resistivity

6|Page

Introduction

There are certain parameters which are to be taken into account for the correct and proper

selection of a slurry pump in any slurry transport system, which are:

Particle size distribution

Solids abrasivity

Solids friability

Particle shape

Particle hardness

Solids content

Flow properties

Slurry density

Corrosivity

Gas content

Temperature

Volume flow rate

Reliability

Cost

Slurry pumps are those types of centrifugal pumps or peristaltic hose pumps which increase the

pressure of solid and liquid particle mixture through centrifugal force and convert the electrical

energy into slurry potential energy and kinetic energy. Many industries such as gold, silver, steel,

iron ore, tin, coal, titanium, lead and zinc, copper, mineral sands, sand and gravel, agriculture

uses slurry pumps for transporting corrosive or abrasive and high concentration slurry. The main

components of a slurry pump are impeller, casing, shaft and bearing assembly, shaft sleeve, shaft

seal and drive type.

7|Page

Introduction

The slurry pumps work on the principle of forced vortex flow that is when a specific mass of

liquid is rotated by an external flow, an increase in the pressure head of the rotating liquid

occurs. This rise of the pressure head at any point of the rotating liquid is directly proportional to

the square of the tangential velocity of the liquid at that same point. This show at the outlet of the

impeller where the radius is more, the increase in pressure head will be high and the liquid will

be discharged at the outlet with high pressure head. So head liquid can be lifted to a high level

due to this high pressure. Figure 1.2 shows the components of a slurry pump.

Transportation of fly ash slurry via pipelines has been recognized as a potential economical and

dependable mode of solid transportation. It also bids various other advantages over the

conventional means of transportation. For improved understanding of the flow characteristics of

these pipelines, investigators throughout the world have been analyzing the flow experimentally

numerically and theoretically. The center of their investigation has been chiefly towards

improvement in the elementary design of these pipelines, which includes a complex reliance on

various geometrical and dynamical restraints.

8|Page

Introduction

Slurry pipelines are regularly used crosswise the world for the shipping of coal ash both fly ash

and also the bottom ash from the power plant to the ash ponds. Majority of the pipelines

functioning today in thermal power plants carries ash at low or intermediate concentrations over

short as well as medium distances. These pipeline systems are very much energy intensive and

also leads to excessive and inordinate wear of pipelines and wastage of water. Moreover, the

current improved consciousness on the road to the inequity in the eco-system and connected

stringent government policies are compelling the thermal power plants to implement

environment friendly transportation systems. Here emerges the high concentration slurry

disposal (HCSD) system has as a preferred choice to transport coal ash in thermal power plants

as it is both economical and environment friendly. Figure 1.3 shows the projected energy usage

in 2035 around the globe.

Figure 1.3: Projected energy usage in 2035 around the globe [3]

Investigators over the years have studied the dense phase conveying of liquid solid mixture in

both horizontal and vertical pipelines and they have found that dense phase flow is possible at

low velocities with overall pressure drop being small. Researchers detected that at a solid

concentration above 40% by weight, fly ash slurries acquit like non-settling homogenous slurry

and the pipe flow can be sustained in laminar regime at moderately lower velocities. So at low

velocities, the pipeline will be exposed to minimal erosion wear. They also concluded that the

safe limit of pumping for a centrifugal pump is a concentration of 50% by weight of coal ash and

above this positive displacement pumps may become essential to pump coal ash slurries.

Moreover a good awareness of slurry rheology is of very much importance principally in the

9|Page

Introduction

High concentration slurry transportation. So it is vital to launch the precise rheological nature of

coal ash slurries at high concentration.

Objectives

The objective of the present work is to conduct a methodical and logical study of coal ash slurry

transportation in a pipeline at higher concentrations by the use of computational fluid dynamics

and study the flow characteristics and pressure drops.

CFD was established during the second half of the 20th century and it became a well-known

analysis tool for single-phase flow analysis during the 90ies with the arrival of commercial CFD

software such as ANSYS CFX and ANSYS Fluent. The role of CFD in the area of multiphase

flow is not as recognized. However, with the improvement of computer resources, making extra

complex analyses probable, along with the assimilation of multiphase flow models in

commercial programs such as those formerly mentioned, CFD is now attaining more importance

also in this area.

Multiphase flow is now a phenomenon in many industrial procedures, amongst them the oil and

gas industry and power plants are the main. Enormous amounts of oil and gas are consumed on a

regular basis and even a small improvement in extraction efficiency will have a noteworthy

impact on revenues for companies in the oil and gas industry. So, discovering reliable analysis

tools for inferring and optimization of multiphase flows is a primacy for these companies.

Numerous error sources occur for numerical simulations and numerical approximation errors

will constantly occur but added error source, which often is hard to detect, is usage error. This

can happen due to accidental application of models, badly chosen constraints or wrongfully

implemented boundary conditions can lead to unphysical and erroneous results. With the

prolonged use of CFD simulations in engineering works it is of high relevance to investigate the

accurateness of commercial codes as well as understanding the selection of models. As not much

published works have been done on judging and studying commercial CFD codes and as the

models and codes may be envisioned and established for a certain multiphase area, what is

precise and appropriate for one business zone might be inappropriate to use for another field.

10 | P a g e

Introduction

Therefore, there is a necessity to examine and associate the models available to develop an

information base for multiphase flow simulations expending commercial software in the oil and

gas business.

An effort is made in this study to develop comprehensive slurry flow model using Computational

fluid dynamics and utilize it to predict pressure drop and validating the results with the

calculated results. A broad CFD model was established in the current study to gain

understanding into the solid-liquid slurry flow in pipelines. In contemporary years, CFD has

become a powerful instrument which can be used in the area like fluid flow, heat and mass

transfer, chemical reactions and associated phenomena by resolving mathematical equations that

manage these processes by means of a numerical algorithm on a computer.

In the case of solid-liquid multiphase flows, the intricacy of modelling surges noticeably and this

remains a zone for more research and improvement. Due to the characteristic complexity of

multiphase flows, from a physical as well a numerical point of interpretation, general related

CFD codes are non-surviving.

Taking into account the restrictions in the published works, the current work has been made

effort to systematically make a CFD based model to analyze and predict the solid concentration

profile in slurry pipeline. The purpose is to inquire into the capability of CFD to model such

complex flow.

In this work, the solid suspension in a fully developed pipe flow was simulated and analyzed.

The two-fluid model based on the Eulerian-Eulerian method beside with a standard k-

turbulence model with mixture properties was taken.

11 | P a g e

Literature Review

CHAPTER 2

LITERATURE REVIEW

12 | P a g e

Literature Review

A comprehensive literature survey is carried out on the slurry transport and Computational fluid

dynamics simulation and analysis of the flow properties. Research and studies on this field was

started a long back and a few of those research works are presented in this chapter. The review is

divided into some modules or sub-reviews such as theoretical studies, experimental studies and

numerical studies. Based on this important review papers, scope and objective of the present

study is established.

This chapter gives an insight into the present state of knowledge about the flow characteristics in

these pipelines by exploring the obtainable literatures. This has also aided to decide the scope of

the present study.

W. Lee Daniels et al.4 [2002] studied about coal fly ash and its beneficial reuse in Appalachian

coal mining environments. They did not simply considered fly ash for the co-disposal of fly ash

in mine fills, but environmentally safe use of it for purposes such as prevention of acid mine

drainage or improvement of mine soil properties for re-vegetation. They concluded that fly ash

can be beneficially used an agricultural amendment as it contains spherical amorphous alumino-

silicate silt-sized particles. Alkaline fly ash acts as a liming material, and many ashes also

provides micronutrients such as B, Mo, and Zn and many other trace elements are found in

phytotoxic levels in fly ash. Fly ash can also be positively employed as a surficial soil

modification to mine spoils or coal waste to enhance water holding capacity, soil pH, and certain

macro- and micro-nutrient levels.

Nigel Heywood5 [2003] has described three alternative methods to reduce pipe friction for

highly viscous often non-Newtonian slurries. First method is by adding soluble ionic compounds

to flocculated slurries which can result in significant pressure drop reductions in pipe flow in the

laminar flow regime. Second is by injecting of water, aqueous polymer solution, heating oil or

polyelectrolytes into the pump discharge pipe using a proper injection ring, thus creating a

lubricating annulus in the pipe for the viscous slurry. Third is by injection of air or inert gas into

the pump discharge pipe to lessen the proportion of the inner pipe wall wetted by viscous slurry.

All these above methods have shown a pressure reduction from 50-90%.

13 | P a g e

Literature Review

Halima et al.6 [2011] has explained the calculation of wall thickness for long distance slurry

pipeline. Taken into account the relatively lesser velocity and around 20 years of expected life

time of pipelines, it was implemented approximately double value for wall thickness. Supply and

discharge pipelines, made of polyethylene of high density material, were installed in sticks about

ten meters long with flange adapters. This technology completely used fly ash and bottom ash

characteristics and all negative influences on production were eradicated.

Seshadri et al.7 [2001] have mentioned that in India, slender phase fly ash slurry disposal system

is by far the most extensively used method of ash transportation in the prevailing thermal power

plants. The normal range of the ash concentration is around 10-15% (by weight). The design is

extremely conservative and accordingly the system is very inefficient from the point of energy

consumption. They have auxiliary shown that medium concentration slurry (Cw=40-50% by

weight) can be easily transported by conventional centrifugal slurry pumps which are being used

for ash disposal at the thermal power plants. For the dense phase fly ash dumping system, they

have opined that, the concentration of ash should be above Cw > 60% by weight. At these higher

concentrations distinct types of slurry pumps are essential to pump the slurry.

Bunn et al.8 [1993] found that the ash slurries shows a non-Newtonian nature with rheological

equation showing either Bingham or yield pseudo-plastic behavior. Different samples of fly ash

collected from different power plants showed a difference in the rheological parameters like

yield stress and Bingham plastic viscosity over a wide range. Thus, it is very vital to measure

these factors before the ash disposal pipeline is planned. Once the rheological behavior of the

slurry is established the head requirements for operating fly ash disposal pipelines at higher

concentrations can be easily calculated. It is probable to reduce the head requirements by adding

additives, which have dispersing/wetting as well as shear thinning properties.

Taimoor Asim et al.9 [2012] worked on getting an optimal sizing of pipeline transporting solid-

liquid mixture. Least cost principle was used in sizing such pipelines, which involves the

determination of pipe diameter for given solid throughput corresponding to the minimum cost.

Transportation of slurry having solids of homogeneously graded particles size has been included

in the detailed analysis. This proposed procedure can be used for designing a pipeline for

transporting any solid material for different solids. The flow parameters considered to the

optimal size of the pipeline was taken in the normal range of operations.

14 | P a g e

Literature Review

Fethullah Canpolat110 [2011] described various coal combustion products and the current

recycling use options of these materials. Materials, productions, properties, potential applications

in production of evolving materials for supportable construction, as well as environmental

impact were studied. He proposed that recycling not only helps disposal costs but also helps to

conserve natural resources and it technical and economic benefits. Some of the uses of fly ash he

mentioned in the study was using it as a constituent in blended cement, as an auxiliary of sand in

making CLSM, in producing of light weight aggregates, in manufacturing high performance

concrete, making super-plasticized structural grade concrete by substituting more than 50% of

cement, as a filler in polymer matrix composite, as a replacement of 30 to 100% silica sand in

manufacturing autoclaved cellular concrete.

Roy Betinol G et al.11 [2009] worked on developing a design of a commercial long distance

slurry pipeline, and the intent of this work was to present the design process and debate any

novel methods and approach used today to guarantee a better, safer and cost-effective slurry

pipeline. It is vital to consider the position of facilities, pipeline route, characteristics of slurry

and quantity of solids to transport to determine the utmost economical pipeline system to use,

while the blend of these parameters describes the economic feasibility of the pipeline transport

system. For designing minimum slurry velocity calculation, friction loss calculation, steady state

hydraulic calculation, and transient hydraulic calculation are to be done. Global Positioning

System (GPS), Leak Detection System (LDS), Expert Control Systems, on line Viscometer, On-

Line Corrosion-Erosion Monitoring System are some of the technologies which has helped in

design and safe operation of the pipelines.

P.Slatter12 [2006] explained that the key issue while designing a plant for slurry handling is the

understanding of the slurry environment. There is always a pressure for using less amount of

water and more amount of slurry concentration in a slurry transportation system, which directly

affects slurry flow. By using Bingham plastic rheological model the impact that slurry rheology

has on transitional pipe flow was studied, particle settling in laminar shear flow, losses in valves

and fittings, centrifugal pump derating and launder flow were also investigated. He concludes

that study of slurry rheology is the main aspect for sound design of a slurry transport system.

Heping Cui et al.13 [2007] gave a review about the flow of biomass multiphase flow

investigating aqueous pulp fiber suspension and slurries, by studying recent experimental

15 | P a g e

Literature Review

techniques and modeling works. They tell that in every flow even at a concentration level of less

than 1% inter-particle forces are to be taken into account. Nuclear magnetic resonance imaging

pulsed ultrasonic Doppler velocimetry, particle image velocimetry, flash X-ray radiography,

dynamic panoramic viewing and laser Doppler anemometry are some advanced experimental

techniques and flow devices which give some solutions by taking into account the inter-particle

forces, but all these techniques have some limitations. They say that industrial biomass processes

are being limited and their potential is not being realized due to the limitations in experimental

techniques. They proposed some advanced softwares and techniques for overcoming these

problems which include capacitance tomography, X-ray tomography, MRI, PDA or PDPA,

gas/particle/liquid tracking techniques, optical probes and imaging techniques.

Experimental studies have provided the database for further developments in the design aspects

of hydraulic transportation system. Researchers study some critical factors like pressure drop,

velocity, concentration, drag, turbulence, phase interaction which will affect the flow

characteristics of fly ash slurry through pipelines. Number of models has been developed and

validated based on the experimental studies reported from time to time.

H.K.Naik et al.14 [2011] evaluated the rheological characteristics of fly ash slurry with and

without additives at varying temperature environment to facilitate smooth flow of materials in

the pipeline. Surfactant like cetyltrimethyl ammonium bromide (CTAB) and a counter-ion called

sodium salicylate (NaSal) was used in the experiment. Surfactant reduces surface tension of the

slurry, thereby increasing its spreading and wetting properties. The best surfactant dosage was

found to be 0.3%, at a temperature ranging from 25C to 30C, as it gives the lowest shear stress.

An improvement in the suspension stability of slurry was also observed. It was observed that fly

ash has got greater potential to be transported in the pipelines with the addition of cationic

surfactant and a counter-ion which will reduce specific energy consumption and water

requirements.

Sunil Chandel et al.15 [2010] from their experiments with coal ash and water resolved that with

increase in concentration, yield stress and Bingham plastic velocity of slurry increases swiftly.

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Literature Review

From experiment it was detected that for slurry at a flow velocity of 2.0m/s approximate increase

in solid concentration from 60.2% to 65.3%, increases the pressure drop by 16%. Relative

pressure drop represents additional head required to transport slurry as compared to water.

Specific energy consumption decreases up to a concentration of 65% by weight and steeply

increases beyond this value.

N.R.Steward et al.16 [2009] tested fly ash and water mixtures in a closed loop pipe system at

solids concentrations extending from 51% to 74% by mass, in three different pipe sizes, 40, 50

and 65 nominal bore. The occurred flow behavior was presented on pipe flow curves, and the

laminar flow data was used to rheologically describe the material as viscoplastic, using the

Herschel-Bulkley rheological model. The data for the flow rate versus pressure gradient shows

that, as the pipe diameter increases the pressure gradient decrease, as the flow rate increases the

pressure gradient increases, as the relative density of the fly ash, or solids concentration,

increases the pressure gradient increases.

Aguilar et al.17 [2006] proposed, use of polymer and surfactant is the most effective drag

reducing technique for turbulent flows. Drag reduction phenomenon for the first time was

observed in 1948. They used tris tallowalkyl ammonium acetate as surfactant. However use of

polymer solutions are frequently too computationally concerning and cumbersome to use and

also usage of polymer solutions for closed loops can cause permanent degradation of the

solution. So, surfactant solutions are favored, since they suffer only temporal degradation when a

certain wall shear stress is surpassed, but recover their drag reducing capacity when shear stress

is decreased.

G.S.F.Shire et al.18 [2008] experimented the pressure drop behavior occurring when ice slurries

flows through constrictions. They suggested that ice slurries when flowing through constrictions

incurs lower pressure drops when compared with water flowing at the same rate through the

same topology. Ice crystals used for this experiment was of 20-50m wide and 100-200m long

and was created using Ziegra ice machine. Ice slurry was circulated through the experimental test

section by using a pump and measurements were taken for flow velocity and pressure drop and

the test was repeated for different ice fractions. A small pressure drop reduction was detected for

ice slurries of over 40% solids when equated with the pressure drop for water at the identical

mean flow rate. The reasons they are telling for this phenomenon is due to complex heat transfer

17 | P a g e

Literature Review

and phase change phenomenon those occurring at the ice-wall interface and also due to the ice

particles obstructing the onset of turbulence in the ice slurries.

Wilson19 [1982] observed that optimization studies done for a range of delivered solid

concentration of 20-60% by volume, for a variety of applied interest flow rates, gives a simple

technique for approximating the pipe diameter and operating velocity which will optimize

pipeline design. He showed that both pipe diameter and operating velocity are less for dense

phase flow than for other types of slurry transport. He also found that the specific energy

consumption for dense phase flow was rather lower than that for coarse particle flow at lower

concentration.

M. Barigou et al.20 [2002] worked on food sterilization process which involves the flow of

solid-liquid mixture in pipes. In food sterilization process it is important to know the minimum

and maximum passage times in the heating and holding sections of the food sterilization system.

The technique used in this experiment was Positron Emission Particle Tracking (PEPT)

technique, which was used to determine the trajectories of almost neutrally-buoyant 510 mm

alginate spheres in viscous non-Newtonian solutions. Hall Effect sensors or visual tracers were

used to measure the particle passage times. Experimental conditions used in this study was wide

and different, they used solid fractions from 16 to 55% volume and the mixture velocity taken

was from 20 to 230 mm/s. Results showed that there is an existence of four different distribution

of passage times (PTD) depending on the flow pattern present. A good agreement was seen

between the predicted and experimentally measured PTDs.

Abhai Kumar et al.21 [2006] studied the pressure drop taking place across a 900 horizontal bend,

through which high concentration fly ash slurry was passed. Slurry concentrations taken for this

study was between 50-65 % (by weight) and the result was used to find out the relative pressure

drop bend loss coefficient and permanent pressure loss. From the experiment it was found out

that the relative pressure drop across the bend in the pipe increases as the concentration increases

at low velocity, and as the concentration increases the bend loss coefficient also increases at any

velocity. A marginal increase in the permanent pressure loss was also noted with increase in

concentration and velocity.

18 | P a g e

Literature Review

Lei Li et al.22 [2002] investigated the pipeline transport of water-fly ash slurry to find out

suitable stabilizing additives for the slurry which will prevent the sedimentation of fly ash during

the pipeline transport. Additives S-194, S-130, CMC, and Vanzan were used in this experiment

and the rheological characteristics and sedimentation stability of the slurry were measured. They

tried to maintain the viscosity of the stable slurry is approximately equal to the viscosity of the

slurry without additives, because the same pump was used, since the viscosity of the slurry

increases with the concentration of the stabilizing additives used in the slurry. It was found out

that s-194 additive gave a better stability to the slurry compared to the other additives used in the

experiment since it had long molecular branches.

L.M.Stanley et al.23 [1973] investigated the flow properties of dairy waste slurries, which is a

non-Newtonian flow, for providing a design data for pumping and transporting dairy manures as

slurry. Hay fibers and wood chips were removed from the collected manure samples by passing

it through a standard sieves with 595 mol openings and viscosity of the slurry was calculated.

Pumping trials were done through pipes of different diameters (3 inch and 4 inch) for different

solid concentrations and pressure drops and sump level readings were taken at 60-s intervals.

These results were compared with the theoretical calculated values and a high level of correlation

was found out between the two. They conclude that the pipe with diameter 3 inch can be

economically used in designing the dairy waste slurry system since it showed less deviation

between the field and calculated results.

R.C.Chen24 [1994] gave a numerical model for slurry flows with solid concentration up to 20%

by volume. A system of differential equations to attain axial velocities of the solid and liquid, the

solid concentration and the liquid turbulent kinetic energy and dissipation rate for solid-liquid

slurry pipe flow in the homogeneous flow regime was established. In spite of the small changes

for 5% slurry flow the turbulent kinetic energy of both 5% and 15% slurry flows was also

detected to increase in the region towards the wall and decrease in the core region. Limitations of

this model were assumptions of zero solid molecular viscosity and isotropic turbulence structure

for dense slurry flows.

19 | P a g e

Literature Review

Gilles et al.25 [2000] improved their own model to enhance its capabilities to predict pressure

drop for high solid concentration, approximately up to 0.63 (by volume fraction) for intermediate

sized particles, especially those with narrow grading. An evaluation with experimental results of

narrowly sized coarse particles of one mm and specific gravity of 1.59 for 0.105 m diameter

pipeline was conducted and a rational matching at low velocities, but a significant deviation

occurred at higher velocities was detected.

Slatter et al.26 [2002] introduced an exciting finding that the Bingham plastic model offers

fundamental advantages over pseudo plastic model. The model is predominantly useful and

robust for the calculation of laminar/turbulent- transition and the connection of rheological

parameters. Bingham plastic model can also be used for head loss predictions of laminar and

turbulent flow.

Dominik Kubicki et al.27 [2012] took experimental data of solid distribution in horizontal

pipelines and modeled using CFD and Discrete Element Method (DEM). Experimental data used

was of pipe diameter in the range from 51 mm to 103 mm, the average sand particle size from 90

m to 4400 m and average solid volume fraction from 0.092 to 0.21. Standard k- model was

used for modeling the turbulent flow. Drag force acting on the particles was modeled using the

Gidaspow formula. The Eulerian Multiphase model implemented correctly predicted the

distribution of solid particles in horizontal pipes for a wide range of particle sizes, pipe diameters

and flow rates. The predictions are close to the experimental data for cases when solids are well

distributed and also when the distribution of solids is poor. When the ratio of pipe diameter to

particle diameter is small, close to 10, the accuracy of Eulerian simulations decreases.

Jouni Syrjnen et al.28 [2009] studied the mixing of sand-water slurry at varying consistencies

in a laboratory scale cylindrical tank equipped with a 450 pitched blade turbine. Solid phases

with volume fractions of 5% and 10 % were investigated. Ultrasound Doppler velocimetry was

used to measure three-dimensional velocity profiles along lines located circumferentially

between two baffles of the tank. Standard k- model was used in turbulence modelling.

Relatively good agreement between the simulated and the measured particle velocities was found

in the central region of the vessel. Deviation of the results was observed with increasing solid

concentration near the wall. Eulerian multiphase model was tested with parameters

20 | P a g e

Literature Review

corresponding meticulously to those used with algebraic slip mixture model. There was a

deviation in the results obtained from measurements more than mixture model predictions.

Tamer Nabil et al.29 [2013] made an attempt to develop a generalized slurry flow model using

the CFD simulation technique to have better insight about the slurry flow in pipelines and its

complexity. Prediction of concentration profile, velocity profile and their effect on pressure drop

taking the effect of particle size into consideration was done using the model. First simulation

was done using a 2D model and the influence of the particle drag coefficient with the different

conditions was studied. Then, 3D model was generated to complete understand and visualize the

slurry flow behavior.

J. Ling et al.30 [2003] introduced a simplified 3D algebraic slip mixture (ASM) model to obtain

the numerical solution in sandwater slurry flow. The RNG k- turbulent model was used with

the ASM model for the study to obtain the precise numerical solution in fully developed

turbulent flow. A block-structured non-uniform grid was used to discretize the entire

computational domain, and to solve the governing equations a control volume finite difference

method was used. The numerical investigation displayed some important slurry flow

characteristics in a fully developed section, such as volume fraction distributions, slurry density,

slip velocity magnitude, slurry mean velocity distributions, and slurry mean skin friction

coefficient distributions. The ASM model gave a good prediction for the liquidsolid slurry flow,

if the critical deposition velocity is lower than the slurry mean velocity. The numerical

predictions for the pressure gradients showed a decent equality with the experimental data.

Jesse Capecelatro et al.31 [2013] did simulation of liquid-solid slurries in horizontal pipes to

study the complex multiphase dynamics related with the functioning conditions above and below

the critical deposition velocities. An entirely conventional immersed boundary method is

employed to reason the pipe geometry on a uniform Cartesian mesh. Two cases were considered,

in the first case a Reynolds number based on the bulk flow of the liquid of 85,000, resulting in a

heterogeneous suspension of particles throughout the pipe cross-section was taken. Data on the

concentration and velocity of the particle phase for this case showed exceptional agreement with

experimental results. In the second case, they considered a lower Reynolds number of 42,660,

leading to the formation of a stationary bed of particles. Three different regions were recognized

in the flow operated beneath the critical deposition velocity, equivalent to a rigid bed, a highly-

21 | P a g e

Literature Review

collisional shear flow, and a freely-suspended particle flow. The maximum variations in

concentration, liquid and particle velocities, and particle diameter were positioned in the region

just above the surface of the bed.

Mikhail et al.32 [2013] compared the turbulence models with the experimental data for the jets

flowing from two nozzles with Ma = 2 and 3, half-angles [theta] a = 8 and 15 degrees, diameter

of the critical cross section d = 10.6 mm to coaxial cylindrical bore with diameter d=85 mm and

4.6, 6 and 13.8 calibers long. Pressure was set full to the upstream of the nozzle, then

intermediate result was noted and then total pressure was increased by 5 atm, and the results

acquired in the earlier step were used as initial conditions. Thus they obtained the reliance of

bottom pressure from the total pressure upstream of the nozzle. Different grids convergence and

the effect of local grid refinement at the walls were examined. But for the calculation of

supersonic flows in the unsteady conditions these turbulence models cannot be directly used, as

in their derivation uses the average flow parameters over time. However, there are low-frequency

vibrations, which belong to quasi-stationary class, i.e. whose period is significantly longer than

the characteristic time of the occurring gas-dynamic processes.

Charlie et al.33 [2013] studied different turbulent models like k- model, k- model and zero

equation model to describe the permeability of turbulent water in an artificial crack and the

results were compared to a universal equation of flow in a porous media based on empirical fit

or Barrs model of a simple general check. Here the k- model was considered to be the most

suitable model for the problem, the main reason for it is the limitations of the other models.

Between the k- model, k- model and zero equation models the discrepancies were small. The

main reason of difference between the models may be due to the nature of the state of interest

and interpretations that were applied to it. The results of this paper are very much important in

the field of hydraulic fracturing and enhanced oil recovery.

22 | P a g e

Mathematical Modelling

CHAPTER 3

MATHEMATICAL MODELLING

23 | P a g e

Mathematical Modelling

The approach adopted by me in studying and solving the problems is mathematical modeling

method. It consists of mainly two parts, they are analytical solution method and simulation and

analysis solver preference. My way of approach is solving the problem through numerical

simulations and validation against theoretical data. Water-fly ash slurry flow through pipelines

will be investigated by both the methods mentioned above to make sure to the credibility of the

results.

The whole transportation system of fly ash slurry in power plants (Figure 3.1) consist of the

following components like,

Slurry mixer

Stirrer

Slurry pump

Fly ash slurry pipe lines

Pressure regulators

Flow regulators

Fly ash receiving ponds

Return water pump

Water pipeline back to the mixer

24 | P a g e

Mathematical Modelling

Physics of fluid flow are mathematically described using equations. Navier-Stokes equations

also known as the continuity equation and the momentum equation are needed to describe the

state of any type of fluid flow and are usually solved for all flows in CFD modeling, see

equations 3.1 and 3.2 respectively. Additionally equations like energy equation and turbulence

equation might also be needed to properly solve the flow problems satisfactorily depending on

the nature of the flow.

.( u ) 0 (3.1)

t

u

.( uu ) p . g (3.2)

t

Where is density, u is instantaneous velocity, p is the pressure, is the viscous stress tensor and

g is gravity vector.

Direct numerical simulations (DNS) are the process of solving the governing equations without

any modeling. But running DNS-simulation is very much time consuming. In practice, all flows

are turbulent and turbulent flow displays time scales of such pointedly different magnitudes that

the mesh resolution needs to be so fine that the calculation times become impractical. Therefore,

modelling is the method to which resort is taken. Turbulent effects and the topic of turbulence

modelling has been the foremost focus of single-phase CFD research for the past couple of years.

Multiphase flow is flow with concurrent presence of diverse phases, where phase cites to solid,

liquid or vapour state of matter. Further modelling is required for Multiphase flow due to

complex behavior of interaction between the phases. So, when doing DNS-simulations for

multiphase flow, modelling is needed.

Gas-Liquid,

Gas-Solid,

25 | P a g e

Mathematical Modelling

Liquid-Solid

Three-Phase Flows.

Added characterization is commonly done conferring to the visual appearance of the flow as

separated, mixed or dispersed flow. These are called the flow patterns or the flow regimes and

the classification of multiphase flow in a particular flow regime is comparable to the importance

of knowing if a flow is laminar or turbulent in single-phase flow analysis. Geometrical

distribution of the phases is described using a flow pattern and the flow pattern significantly

affects phase distribution, velocity distribution and etcetera for a certain flow condition. A

number of flow regimes prevail and the likely flow patterns differ depending on the geometry of

the flow domain. Figure 3.2 shows the flow patterns in solid-liquid flow.

26 | P a g e

Mathematical Modelling

Models are used to be able to define and envisage the physics of multiphase flow. As formerly

mentioned, modelling of multiphase flow is very intricate. In addition, there are also confines in

time, computer ability etcetera when executing numerical studies. This has led to the

implementation of models that can reason for different levels of information, implicating

different levels of accuracy, and are appropriate for different multiphase flow applications. Some

of these modelling approaches are introduced below.

In Euler-Lagrange approach, particles are traced on the level of a single particle where particle

denotes either a solid particle or a gas/fluid bubble/droplet. Conservation equations are

deciphered for the continuous phase and the particle phase is followed by solving the equations

of motion for each particle as shown in equations 3.3, 3.4 and 3.5 below.

f f

.( f f u f ) Smass

t (3.3)

f f

.( f f u f u f ) f p f . f Sp f f g 0 (3.4)

t

u p

F (3.5)

t

Where is the volume fraction, Smass is a mass source term existing in the case of exchange of

mass between the phases, Sp is the momentum source term existing in case of exchange of

momentum between the phases and F is the force. Subscripts f and p denotes to the fluid and

particle phases, respectively.

The forces acting on particles differ depending on the flow situations. The drag force is usually

included and other forces that can be of prominence are for example the lift force, the virtual

mass force and the history force. When executing numerical modelling it is up to the modeller to

evaluate which forces that are of importance is to be included to the right hand side of the

equation 3.5. Adding extra forces to model increases accuracy but also surges complexity.

27 | P a g e

Mathematical Modelling

Coupling between the continuous phase and the dispersed phase is attained through the source

terms. These are included also in the equation for the dispersed phase but are not clearly shown

here as they are a portion of the right hand side. Integration of equation 3.5 gives the position of

the dispersed phase.

As this modelling approach resolves information on the level of a single particle it is quite

computationally costly. To reduce the computational cost one can pick to track clusters of

particles instead. But, this method is still computationally expensive and therefore Euler-

Lagrange modelling is apt for dilute dispersed flow, means flows with a low volume fraction of

the dispersed phase.

In Euler-Euler method, different phases are dealt statistically as interpenetrating continua. Since

the volume of a phase cannot be engaged by other phases, the concept of phasic volume fraction

is presented. These volume fractions are supposed to be continuous functions of space and time

and their sum is equivalent to one. Conservation equations for every phase are resolved to obtain

a set of equations, which have comparable structure for all phases. These equations are secured

by providing connections that are attained from empirical information or, in the case of granular

flows, by implementing of kinetic theory. The governing equations for a two-fluid model with

two continuous phases are shown below.

k k

.( k kU k ) 0

t (3.6)

k kUk

.( k kU k Uk) k P k . k k k gk Sk 0

t (3.7)

k

.( k U k ) 0

t (3.8)

Where U is the mean velocity field and P is the mean pressure of the phases. The subscript k

refers to the k:th continuous phase.

28 | P a g e

Mathematical Modelling

Figure 3.3 shows the different multiphase phase models. Three different Euler-Euler multiphase

models are available:

The Mixture Model

The Eulerian Model

designed for two or more immiscible fluids where the situation of the interface amid the fluids is

of interest. In this model, the fluids share a sole set of momentum equations, in each

computational cell the volume fraction of each of the fluids is traced throughout the domain.

29 | P a g e

Mathematical Modelling

Applications of the VOF model comprises stratified flows, free-surface flows, filling, sloshing,

the motion of large bubbles in a liquid, the motion of liquid after a dam breakdown, the

calculation of jet breakup, and the steady or transient tracing of any liquid-gas interface.

The mixture model is intended for two or more phases, either fluid or particulate. Likewise in the

Eulerian model, this model considers the phases as interpenetrating continua. The mixture model

resolves the mixture momentum equation and recommends relative velocities to describe the

dispersed phases. Usages of the mixture model comprise particle-laden flows with low loading,

bubbly flows, sedimentation, and cyclone separators. The mixture model can also solve problems

of dispersed phases without relative velocities to model homogeneous multiphase flow.

Among all the multiphase models, Eulerian model is the most complex. It resolves a set of n

momentum and continuity equations for each phase. The pressure and interphase exchange

coefficients are used to achieve coupling in this model and the way in which this coupling is

dealt depends upon the type of phases involved. Granular or fluid-solid flows are handled

differently than non-granular or fluid-fluid flows. For granular flows, the properties are attained

from application of kinetic theory. Momentum exchange among the phases is also dependent

upon the type of mixture being modeled. Usages of the Eulerian multiphase model include

bubble columns, risers, particle suspension, and fluidized beds.

The first and foremost step in resolving any multiphase problem is to determine which of the

regimes best exemplifies our flow. Some guidelines for choosing the most appropriate model for

a given problem are:

For St<<1.0, the particle will trail the flow strictly and any of the three models (discrete

phase, mixture, or Eulerian) is appropriate. One can therefore go for the least expensive

(the mixture model, in most cases), or the most appropriate taking other factors too.

30 | P a g e

Mathematical Modelling

For St > 1.0, the particles will traffic independently of the flow, either the discrete phase

model or the Eulerian model is appropriate.

For St 1.0, again any of the three models can be used. One can select the least expensive

or the most appropriate taking other factors.

If a wide distribution of the dispersed phases is involved, the mixture model may be

desirable. But if the dispersed phases are concentrated just in quotas of the domain, one

should follow the Eulerian model instead.

If interphase drag laws that are applicable to system accessible (either within FLUENT or

through a user-defined function), the Eulerian model can generally provide more precise

results than the mixture model.

If the interphase drag laws are not known or their pertinence to system is problematic, the

mixture model may be a superior choice.

If the problem to be solved is simple and needs less computational effort, the mixture

model may be a healthier option, since it solves a fewer number of equations than the

Eulerian model.

If accuracy is more significant than computational exertion, the Eulerian model is a

superior choice. But one thing to be remembered is that, the complexity of the Eulerian

model can make it less computationally stable than the mixture model.

Fluctuations occurring in the velocity field blend transported amounts such as momentum and

energy and cause the transported quantities to vary as well. These fluctuations can be of a very

minor scale and consequently can create tremendously huge computational expenditures for

applied engineering calculations. An improved set of equations that involve much less

computational expenditure are used. This is achieved by time-averaging the instantaneous

governing equations which then include added unknown variables. Turbulence models are

required to solve these unknown variables.

No lone turbulence model can be universally applied to all conditions. Always remember that

some consideration has to be taken when selecting a turbulence model which includes; physics

31 | P a g e

Mathematical Modelling

involved in the flow; level of accuracy; and computation resources accessible. Mainly two

turbulence models will be discussed in here they are k- and k- turbulence models.

The k- model is one of the most extensively used turbulence models as it delivers robustness,

economy and judicious accuracy for an extensive variety of turbulent flows. The two transport

equations k and independently solves for turbulent velocity and length scales. Figure 3.4 shows

the different k-models.

Realizable k- Model

Renormalization Group (RNG) k- Model

32 | P a g e

Mathematical Modelling

Generation and destruction terms which are present in the equation of

The way in which turbulent viscosity is calculated.

The k- model has the advantage that is that it does the near wall treatment. The model is

comparatively more robust and accurate. The model assume that the turbulent viscosity is linked

to the turbulent kinetic energy and the turbulent frequency. It solves two equations, one for

turbulent kinectic energy and other for turbulent frequency. The k- model is numerically more

stable than other models. One of its disadvantge is that it is very sensitive to inlet free stream

turbulences. Figure 3.5 shows the different k- models. The k- model is also categorized into

two, they are:

Shear Stress Transport (SST) k- Model

33 | P a g e

Mathematical Modelling

Both of the two variations of the k- model uses similar transport equations for the k and , but

the shear stress transport (SST) model differs from standard model by using a modified turbulent

viscosity equation for the transportation of the principal turbulent shear stresses.

Pressure drop is the most important parameter for solid liquid transport in mineral and other

solids handling industry. Power consumption and successively the whole economics of the

hydro-transport hinge on it. For this cause, pipeline design is primarily based on optimization in

pressure drop and preliminary investment. There are fat number of empirical and semi empirical

correlations accessible in literatures to predict pressure drop. Most of these equations have been

established based on limited data embracing of even or narrow size-range particles with very low

to moderate concentrations. As the relationships are empirical in nature, their pertinence is

inadequate e.g. the correlations developed for sand-water slurry flow do not crop promising

results when they were implemented on coal-water slurry flows. These correlations are

susceptible to great ambiguity as one departs from the limited database that backs them.

Transportation of slurries via pipeline is very much common in mineral and petrochemical

industries and its enormous power consumption are getting consideration in recent years. Need

and advantage of precisely calculating the vertical solid concentration profiles and the pressure

drop of slurry pipelines in the course of design phase is enormous as it helps in superior selection

of slurry pumps, optimization of power consumption and also helps to make best use of

economic possibilities. Even though the large area of application, the accessible published

models telling the slurry pressure drop and concentration profile do fully satisfy engineering

requirements. Efforts are still on to cultivate more rational model for estimation of pressure drop

and concentration profile in pipes and in this area.

Pressure drops in pipelines are mainly caused due to the following reasons, they are:

Friction

Vertical Pipe Difference or Elevation

Changes of Kinetic Energy

34 | P a g e

Mathematical Modelling

For determining pressure drop along a pipeline when a fluid flows through it is done by adopting

the following steps in the given order.

ud

Re (3.9)

From equation 3.9 if it gives Reynolds Number < 2320, then it is a laminar flow

64

For laminar flow,

Re (3.10)

1 2.51 k

For turbulent flow, 2log 0.269 (3.11)

Re d

c) Determine pressure drop ( p )

l

p u 2

d 2 (3.12)

Where, l is length of pipe (m)

is the density of the fluid (kg/m3)

35 | P a g e

Mathematical Modelling

Present work is to conduct a methodical and logical study of fly ash slurry transportation in a

pipeline at higher concentrations by the use of computational fluid dynamics and also to study

the rheological properties and pressure drops. ANSYS Fluent software has been used to model

and simulate the flow through pipeline and its analysis is done and then it is validated against

theoretical data.

A three dimensional planar geometry is created due to the symmetry of the model and to save the

simulation and calculation time. The geometry cell is used to create, edit, or import geometry

that is used for analysis. For creating geometry for analysis, double-click on the Geometry cell;

the Design Modeler window will be displayed (Figure 3.6).

Length of pipe = 20 m

(a) (b)

Figure 3.6: (a) Pipe geometry along the length, (b) Pipe geometry a planar view

36 | P a g e

Mathematical Modelling

Extrusion method is used for the geometry creation. The geometry created has a volume of

1.9635 m3, a surface area of 25.904 m2, 4 faces, 6 edges and 4 vertices.

A hexa sweep mesh is used here for meshing the model created. We can use the mesh component

system to create and/or open geometry or mesh files. A grid independence test was conducted to

find the apt number of grids which can be effectively used in meshing and found out to be 600

number of sweep divisions (Figure 3.7).

Number of nodes created in meshing is 24040 and number of elements created is 17400.

A pressure based solver is used for simulation process. Since the concentration of slurry flow

which is to be simulated is very high, Eulerian multiphase model with implicit volume fraction

parameter is employed. The k- turbulence model is selected over the k- turbulence model after

trial simulations where carried out and observing that the results did not show any variations, but

the simulation time for k- model was more compared to k- model, which encouraged the

selection of k-model over k- model.

37 | P a g e

Mathematical Modelling

Fly ash and water properties are entered in the phase area of the problem setup. Intend is to

measure pressure drop at various flow velocities at various concentrations in the range of 50-

70% by weight. Specific gravity of fly ash taken is 2.01. Granular diameter of the fly ash is taken

as 75 m. Different velocities considered for simulation process are 3 m/s, 3.5 m/s, 4 m/s, 4.5

m/s and 5 m/s. Rheological properties of fly ash slurry are given in Table 3.1.

% Con (Cw) Temp Stress Viscosity Viscosity slurry Remarks

(by weight) (0C) y (Pa) p ( 10-3) w ( 10-3) Viscosity

(Pa-s) (Pa-s) r

Boundary Conditions

Both the phases are given velocities for each concentrations

In the inlet zone fly ash is each also given volume fractions according to the

concentration flowing through the pipe

38 | P a g e

Mathematical Modelling

In the pressure velocity coupling coupled scheme is taken and spatial discretization uses first

order upwind for momentum, volume fraction, the turbulent kinetic energy and the turbulent

dissipation rate. In monitors 1e-06 is the residual used for equations with an absolute convergence

criterion. Solution initialization is done by using standard initialization with computing from the

inlet. Number of iteration given for the solution is 4000 and calculation part is started.

Theoretical equations and parameters are used for validating the results got in computational

fluid dynamics method. For this, equation for getting Reynolds number (3.9), equation for

calculating pipe friction coefficients (3.10) and (3.11), pressure drop equations (3.12) are used.

39 | P a g e

RESULTS AND DISCUSSION

CHAPTER 4

40 | P a g e

RESULTS AND DISCUSSION

Here the viscosity of fly ash slurry is 3.2 10-3 Pa.s. The graph plotted for pressure drop between

simulated values and calculated values are given in the figure 4.1 and the figure 4.2 shows the

pressure contour obtained for transportation of 50% concentration by weight of fly ash slurry.

3500

Simulated

3000

Pressure Drop (Pa/20m length of pipe)

Calculated

2500

2000

1500

1000

500

0

3.0 3.5 4.0 4.5 5.0

Flow Velocity (m/s)

Figure 4.1: Comparison between calculated and simulated pressure drop at 50%

concentration

41 | P a g e

RESULTS AND DISCUSSION

Here the viscosity of fly ash slurry is 11.3 10-3 Pa.s. The graph plotted for pressure drop

between simulated values and calculated values are given in the figure 4.3 and figure 4.4 shows

the pressure contour obtained for transportation of 60% concentration by weight of fly ash slurry.

3500

3000 Simulated

Pressure Drop (Pa/20m length of pipe)

Calculated

2500

2000

1500

1000

500

0

3.0 3.5 4.0 4.5 5.0

Flow Velocity (m/s)

Figure 4.3: Comparison between calculated and simulated pressure drop at 60%

concentration

42 | P a g e

RESULTS AND DISCUSSION

Here the viscosity of fly ash slurry is 44.9 10-3 Pa.s The graph plotted for pressure drop

between simulated values and calculated values are given in the figure 4.5 and the figure 4.6

shows the pressure contour obtained for transportation of 65% concentration by weight of fly ash

slurry.

3500

3000 Simulated

Pressure Drop (Pa/20m length of pipe)

Calculated

2500

2000

1500

1000

500

0

3.0 3.5 4.0 4.5 5.0

Flow Velocity (m/s)

Figure 4.5: Comparison between calculated and simulated pressure drop at 65%

concentration

43 | P a g e

RESULTS AND DISCUSSION

Here the viscosity of fly ash slurry is 136.5 10-3 Pa.s. The graph plotted for pressure drop

between simulated values and calculated values are given in the figure 4.7 and the figure 4.8

shows the pressure contour obtained for transportation of 68% concentration by weight of fly ash

slurry.

3500

Simulated

3000

Calculated

Pressure Drop (Pa/20m length of pipe)

2500

2000

1500

1000

500

0

3.0 3.5 4.0 4.5 5.0

Flow Velocity (m/s)

Figure 4.7: Comparison between calculated and simulated pressure drop at 68%

concentration

44 | P a g e

RESULTS AND DISCUSSION

Here the viscosity of fly ash slurry is 201.0 10-3 Pa.s. The graph plotted for pressure drop

between simulated values and calculated values are given in the figure 4.9 and the figure 4.10

shows the pressure contour obtained for transportation of 70% concentration by weight of fly ash

slurry.

3500

Simulated

3000

Pressure Drop (Pa/20m length of pipe)

Calculated

2500

2000

1500

1000

500

0

3.0 3.5 4.0 4.5 5.0

Flow Velocity (m/s)

Figure 4.9: Comparison between calculated and simulated pressure drop at 70%

concentration

45 | P a g e

RESULTS AND DISCUSSION

The pressure drop measurements both by simulation and theoretical procedures for fly ash slurry

in a 0.5 meter pipe for solid concentrations 50%, 60%, 65%, 68% and 68% by weight are

graphically shown in for velocities 3, 3.5, 4, 4.5 and 5 m/s are shown in figure 4.11 and 4.12

respectively.

3500

Cw=50%

3000 Cw=60%

Pressure Drop (Pa/20m length of pipe)

Cw=65%

2500 Cw=68%

Cw=70%

2000

1500

1000

500

0

3.0 3.5 4.0 4.5 5.0

Flow Velocity (m/s)

Figure 4.11: Simulated values of pressure drop variation for fly ash slurry at different

concentrations

3500

Cw=50 %

3000 Cw=60%

Pressure Drop (Pa/20m length of pipe)

Cw=65%

2500 Cw=68%

Cw=70%

2000

1500

1000

500

0

3.0 3.5 4.0 4.5 5.0

Flow Velocity (m/s)

Figure 4.12: Calculated values of pressure drop variation for fly ash slurry at different

concentrations

46 | P a g e

RESULTS AND DISCUSSION

From the graphs and values obtained from both theoretical method and computational method

gives a lot of resolutions. When the concentration is increased from 50 to 60% by weight of fly

ash the pressure drop got increased by 15%, and when the concentration is increased from 60 to

65% by weight of fly ash the pressure drop got increased by 14%. An increase of 17% in

pressure drop is observed when the concentration is increased from 65 to 68% by weight of fly

ash. The reason behind the increase in pressure drop with concentration is, with the increase in

concentration of the fly ash slurry the viscosity gets increased and the effects of fluid friction,

pipe friction and eddies formation. Even for a small change in slurry concentration the increase

in viscosity is enormous. When the viscosity is increased it leads to the increase in friction

between the fluid layers and also increases the friction between the pipe and fluid flowing. This

is the main reason behind the drastic increase in pressure drop even for a small increase in slurry

concentration.

Another issue noticed from the investigation is that for every concentration studied the velocity

when changed from 4.5 to 5 m/s a drastic increase in pressure drop is observed and the pressure

drop values given by the computational method is greater than the values given by theoretical

methods.

So it is concluded that slurry with concentration of 65% by weight of fly ash is the desired

concentration to be transported in slurry pipelines with lowest rate of pressure drop. Taking the

specific energy into account 65% is the concentration which can be economically transferred

through a pipeline in industries. The specific energy consumption is defined as the amount of

energy required for transporting one ton of slurry over a distance of one kilometer. Also the

desired velocity which can be used for transporting slurry is 4.5 m/s because further increase in

velocity gave a tremendous increase in the pressure drop. So it shows that we cant increase the

velocity as per our wish for fast transport of the slurry, which may lead to negative impact on

transportation of slurry.

47 | P a g e

RESULTS AND DISCUSSION

Volume fraction of a component in a mixture or fluid is the ratio between the components

volume in the mixture to the total volume of the mixture. It is dimensionless and has unit 1 and is

expressed as a number and is sharing the same concept of volume percentage. Sometimes

volume fraction is also called as volume concentration.

It was seen that the volume fraction of fly ash remained uniform in the beginning of the flow and

towards the end more volume fraction distribution is found at the bottom portion of the pipe and

comparatively low at the top part of the end portion of pipe. The main reasons for this difference

in volume fraction distribution along the length of the pipe are sedimentation of fly ash in the

slurry, high viscosity of slurry flowing and high density of the fly ash slurry. The contour plot of

volume fraction distribution is shown in figure 4.13.

48 | P a g e

RESULTS AND DISCUSSION

Eddy viscosity is caused due to the turbulent transfer of momentum by eddies which gives rise to

an internal fluid friction, which can be compared to molecular viscosity in laminar flow, but

taking place on a much bigger scale. Eddy viscosity is always a function of the flow and is more

for fluids with high turbulence.

It is observed that many variations are taking place in eddy viscosity along the length of the pipe

throughout the flow. In the beginning the rate of eddy viscosity is maximum, which in the later

part decreases and towards the end of the pipe it becomes minimum.

Pressure drop is the main reason behind these variations in eddy viscosity. Other main reasons

for this variation in eddy viscosity are turbulence formation and boundary layer effect. The

contour plot of eddy viscosity is shown in figure 4.14.

49 | P a g e

RESULTS AND DISCUSSION

Turbulence kinetic energy is mean kinetic energy per unit mass. Turbulence and turbulent kinetic

energy are very strongly related to each other as the intensity of turbulence decides the intensity

of the turbulent kinetic energy. Idea of turbulent kinetic energy is very much similar to that of

kinetic energy, since in a flow the energy can be divided into two they are mean kinetic energy

of the flow and turbulent kinetic energy of the flow.

It is observed that in the fly ash slurry flow, turbulence kinetic energy is minimum towards the

end of the pipe and maximum at the beginning. As the main reasons behind creation of

turbulence kinetic energy (TKE) are fluid shear, eddy formation and fluid friction it gives a clear

explanation for the maximum turbulence at the beginning of the pipe. In the beginning the

velocity of flow is more so the mean kinetic energy will also be more, so turbulence kinetic

energy is more in the beginning. The contour plot of turbulence kinetic energy is shown in figure

4.15.

50 | P a g e

CONCLUDING REMARKS

CHAPTER 5

CONCLUDING REMARKS

51 | P a g e

CONCLUDING REMARKS

5.1 CONCLUSION

Fly ash slurry with concentration of 65% by weight of fly ash is the desirable

concentration to be transported in slurry pipelines with lowest rate of pressure drop.

The most desirable velocity for slurry transport in pipeline is found out to be 4.5 m/s

since beyond this velocity a great increase in pressure drop was detected.

For a certain slurry concentration it is observed that as the velocity increases the pressure

drop also gets increased consequently.

For a certain velocity the pressure drop increases with increase in concentration of the

slurry.

Specific energy consumption increases with increase in concentration and velocity of

flow, so a concentration of 65% weight of fly ash and 4.5 m/s velocity is the desirable

concentration and velocity for economical transport with least specific energy

consumption.

Even for small increase in concentration of fly ash slurry the increase in viscosity is

enormous.

When the viscosity is increased it leads to the increase in friction between the fluid layers

and also increases the friction between the pipe and fluid flowing. This is the main reason

behind the drastic increase in pressure drop even for a small increase in slurry

concentration.

The pressure drop values given by the computational method is greater than the values

given by theoretical methods, because in computational process a lot of flow factors are

taken into account compared to theoretical procedures undertaken.

The volume fraction of fly ash remained uniform in the beginning of the flow and

towards the end more volume fraction distribution is found at the bottom portion of the

pipe and comparatively low at the top part of the end portion of pipe.

Many variations are taking place in eddy viscosity along the length of the pipe

throughout the flow. In the beginning the rate of eddy viscosity is maximum, which in the

later part decreases and towards the end of the pipe it becomes minimum.

52 | P a g e

CONCLUDING REMARKS

In the beginning the velocity of flow is more so the mean kinetic energy will also be

more, so turbulence kinetic energy is more in the beginning.

A lot of time can be saved by using CFD method for calculation of pressure drop

compared to manual calculations.

Eulerian model is the apt multiphase model that is to be used in simulation of slurry flow

because flows with high concentration needs Eulerian model for getting accurate results.

Usage of sweep mesh method in meshing process gives high solver accuracy and also

reduces mesh cell counts which leads to a serious speedup in calculation time.

Simulation time for k- model was more compared to k- model, which encouraged the

selection of k-model over k- model.

The work can be expanded for other slurries also, like minerals, ores, gold, silver, copper

etcetera.

The study can to be extended to fly ash slurries in which additives for reducing viscosity

are added.

Experimental validation.

CFD modeling capability is to be extended to model slurry flow in vertical pipeline, pipe

bends and through pipe fittings and pressure drop for each case can be found out and

optimized.

53 | P a g e

References

REFERENCES

54 | P a g e

References

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57 | P a g e

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